Tuftless mattress



OC. 29, 1935. W S BECKER TUFTLESS MATTRESS Filed Aug. 2, 1934 3 Sheets-Sheet 1 oct. 29, 1935. w. s. BECKER 2,018,173

TUFTLES S MATTRES S Filed Aug. 2, 1934 5 Sheets-Sheet 3 WALTER 5. EcKER Patented Oct. 29, 1935 UNITED srATi-:s

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il@ F Y Application August 2,

3 Claims.

The invention has for an object to provide a mattress, cushion or similar article which is so constructed as to eliminate the necessity of tuft- .5 Y, Further, the invention has for an object to provide a tuftless matress of an economical construction, one which will maintain its shape for an indefinite time, and one wherein a large portion of its resiliency is obtained through the use of coiled springs.

Further, it is an object to provide a mattress whose coiled springs need not be individually enclosed infabric envelopes.

Further, it is an object to provide a mattress whose core assembly includes a coiled spring unit which is itself enclosed in a resilient textile body that is composed of layers of burlap, hair felt, crepe paper, and cotton felt, or their equivalent, Said textile body being produced in sheets with the several layers stitched. together, preferably by parallel rows of loose stitches.

Further, it is an object to provide a mattress whose core assembly is covered with a layer (single or laminated) of cotton felt (or its equivalent) sew-ed to a cheesecloth sheet by parallel rows of stitches to support the cotton felt while it is being laid on and around the core assembly, the Whole being then encased in a fabric envelope, the edges of which are sewed into rolls, thereby holding the cheesecloth supported layer of padding against shifting within the fabric envelope.

Further, it is an object to provide a coiled spring core assembly in which the several springs d o not project into or through the material which surrounds them, and in which the surrounding envelopes are not used for the purpose of keeping the coils of the spring unit in position relatively one to another, as is the case, for example, in Letters Patent No. 1,755,715.

Further, it is an object, in one embodiment of the invention, to provide a mattress whose sides and ends are composed of a double thickness of material, thereby giving a marginal structure of greater rigidity than that of the top and bottom of the mattress and preventing the mattress from being permanently compacted at the edge by the weight of a person sitting or lying on the edge thereof.

Other objects will in part be obvious and in part be pointed out hereinafter.

To the attainment of the aforesaid objects and ends, the invention still further resides in the novel details of` construction, combination and arrangement of parts, all of which will be rst fully described in the following detailed description, then be particularly pointed out in the appended claims, reference being had to the accompanying drawings, in Which:-

1934, Serial No. 738,134

Figure 1 is a cross section on the line I--l of Figure 2.

Figure 2 is a plan view of a portion of a spring core-unit.

Figure 3 is a detail sectional perspective view 6 of the spring cover. i

Figure 4 is a detail cross section of a mattress embodying the invention.

Figure 5 is a detail sectional perspective view of one corner of a mattress core-assembly showing a slight modication.

Figure 6 is a detail sectional perspective view of the core-assembly covering layer of cotton felt or padding.

In the drawings in which like numerals of reference indicate like parts in all the gures, it will be noted particularly by reference to Figures 1 and 2, that the spring core-unit which constitutes a part of my invention comprises a number of rows of coils, the coils of a row being ,20 secured together and adjacent rows being connected by longitudinal, flexible tie rods.

In the drawings the individual coils are shown composed of top and bottom loops l connected by intermediate spirals 2. The diameter of the coil at the spiral 2 is slightly less than the diameter of the top and bottom loops l thereof so as to prevent adjacent spirals from interlocking when the mattress is in use.

It' will be seen that the springs of each row 30 have their top and bottom loops I connected together by tie clips 5 which also embrace the longitudinal exible tie rods 3, the latter being preferably composed of metallic cores 4 wound with a fabric covering. It will be noted that the several coils constituting a roware arranged with their top and bottom loops l close together, whereas adjacent rows are preferably spaced apart as shown in Figure 2.

It will be seen from the foregoing that the 40 structure shown in Figures 1 and 2 constitutes a complete unit and is used as the core proper'of the mattress. The core-assembly includes the core proper and a surrounding envelope therefor which is preferably composed of a suitable coarse 45 mesh fabric 8 (preferably burlap) which forms i the base of the core cover and comes into direct contact lwith the springs.

Surrounding the burlap 8 is a layer of suitable thickness of hair felt or hair padding, this being 50 covered by a sheet 8 of crepe paper or other suitable flexible and resilient material impervious to the hairs of the padding l. Over the crepe paper sheet 8 is placed an outer layer of cotton felt or padding 9. The spring envelope, composed 5 of the parts 6, l, 8, and 9, is preferably manu factured in the form of a bat or hat sheet, as indicated in Figure 3, and the parts 6, 1, 8, and 9 are held together in superposed relation by stitching the same as at l0 with parallel rows 50 of stitches at comparatively wide intervals apart.

The core-assembly may be made up by placing the sheets shown in Figure 3 over and under the spring core, folding down the ends and sides to overlap, as indicated in Figure 4, with parallel laps, or the material may be formed to give beveled laps, as indicated in Figure 5, if desired.

With the construction shown in Figure 4, however, the marginal wall of the matress (ends and sides) is made of double thickness so as to increase the resistance to mashng down the sides of the mattress by persons sitting thereon.

Over the core-assembly is placed'a layer II of suitable thickness, the layer II being composed of cotton felt batting or padding and this padding layer II is laid in direct contact with the outer layer 9 of the core-assembly so that it may be held firmly in place thereon by interengagement of the bers of the layers 9 and II.

The layer I I is preferably prepared in the form of a bat, as indicated in Figure 6, and in order to give the necessary strength to the layer II during its manipulation to place it in position over the core-assembly I preferably stitch to the outer face of the layer Il a sheet of cheesecloth I6, the stitching being indicated at II.

Two' layers of padding, shown in Figure 6, are employed, one over the topi and one under the bottom of the core-assembly with the sides and ends folded down and preferably beveled-lap joined, as at I9.

I2 designates the fabric envelope or case, usually made of ticking, and this is built around the layer II and the edges are formed into rolls I3 by suitable stitching I4.

In making the mattress the outer envelope or covering is preferably made of a top and bottom sheet and a marginal sheet constituting the sides and ends of the mattress, the marginal sheet being sewn to the top and bottom sheets as at I8, a beading cord strip i5 being sewn in at the joint if desired (see Figure ll).

It will be observed by reference to Figure 4 that the stitching Iii secures the bat II and its cheesecloth sheet I6 to the envelope or casing 'I2 and makes it unnecessary to sew the bat to the casing anywhere else.

By providing the layer I of felted hair it adds greatly to the resiliency of the mattress. Were it not for the crepe paper sheet 8, however, the hair of the layer l would work through the layers 9 and II and the ticking envelope I2. 'Ihe use of crepe paper sheetingI 8 prevents this. While I prefer to use the crepe paper, it is obvious that any other similar impervious-to-hair material which is sufficiently flexible and elastic may be employed, as for instance a sheet of rubber or rubberized fabric. The crepe paper, however, serves well and is less expensive than the materials mentioned.

It will be noted, particularly by reference to Figures 4 and 5, that the spring unit is not interlocked with the surrounding envelope, nor is the envelope sewn or tied to the spring unit. The spring unit is kept from shifting around and becoming displaced by reason of the fact that its elements are tied to one another to constitute a unitary structure and the resiliency of the surrounding envelope is such that it will belly into the loops i and into the spaces between adjacent rows of springs sufficiently to hold the structure which surrounds the spring core-unit in its proper position with respect to that unit at all times regardless of the movements imparted to the mattress in use.

It will also be observed that with my con- 5 struction it is not necessary to produce formations in the structure surrounding the spring unit such as are known in the art as biscuits" or biscuit formations. The stitching may be in one direction only and it is not necessary to cross 10 stitch the materials in order that they may function properly in the complete assembly.

From the foregoing description, taken in connection with the accompanying drawings, it is thought that the construction, operation and advantages of the invention will be clear to those skilled in the art.

What I claim is:

1. Al mattress comprising a spring assembly presenting a coiled spring core, an envelope wall 0 for the same composed of a sheet of coarse woven fabric located adjacent the spring core, a layer of hair felt over the coarse woven fabric, a sheet of dense ilexible material over the layer of hair felt and a cotton felt layer over the sheet of dense flexible material and rows of stitching holding said sheets and layers together; an outer layer of cotton felt surrounding said wall and held firmly in place thereon by interengagement of the fibers of said outer layer and said wall; 30 a cover fabric housing the aforesaid structure; and a cheesecloth sheet sewn to the outer face of said outer layer.

2. A mattress comprising a spring assembly presenting a. coiled spring core and an imperforated envelope wall therefor, said wall being composed of an upper layer and a lower layer having their sides and ends lap-jointed and lying over the sides and ends of the spring core, said envelope layers each comprising a sheet of imperforated coarse woven fabric located adjacent the spring core, a layer of hair' felt over the coarse woven fabric, a sheet of dense ilexible material over the layer of hair felt, a cotton felt layer over the sheet of dense exible material and rows of stitching holding said sheets and layers together; anv outer layer of cotton felt surrounding said wall an'd held firmly in place thereon by interengag'en'ient of the fibers of said outer layer and said Wall; n and a cover fabric housing the aforesaid structure.

3. A mattress comprising a spring' assembly presenting a coiled spring core and an imperforated envelope wall therefor, said wall being Y. composed of an upper layerand a lower layer 55 having their sides and ends lap-jointed and' lying over the sides and ends of the spring core, s'aid envelope layers each comprising a sheet of imperforated coarse woven fabric located adjacent the spring core, a layer of hair' felt over the 60 coarse woven fabric, a sheet of dense eXible material over the layer of hair felt, a cotton felt layer over the sheet of dense flexible material and rows of stitching holding said sheets and layers together; an outer layer of cotton felt surrounding said wall and held firmly in place thereon by interengagement of the libres of said outer layer and said wall, a cheesecloth sheet sewn to the outer face of said cotton felt; anda cover fabric housing the aforesaid structure.

WALTER S. BECKER. 

